Chloride/sulfate removal system

ABSTRACT

The liquid cooling spray in a gas conditioning chamber is modified by the addition of an alkali to scrub sulfur dioxide and other acid forming gases and a separation unit to remove particles that may contain either unreacted alkali or salts of the acid forming gases. A slurry of fine particles of hydrated lime is injected into the liquid coolant under conditions that result in kernels of controllable size that contain the alkali or salts from reactions with the acid forming gases. The modified cooling liquid provides for a high sulfur dioxide collection efficiency at a low molar ratio of alkali to sulfur, while the specified kernel size range allows for efficient removal of the kernels from the gas.

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application is a continuation-in-part of application Ser. No. 09/064,015, filed Apr. 20, 1998.

FIELD OF THE INVENTION

[0002] This invention relates generally to the field of air pollution control, and is particularly directed to a system to remove condensed scrubbing products from a gas that has been scrubbed of sulfur dioxide and other acid-forming gases.

BACKGROUND OF THE INVENTION

[0003] Over the past several decades the control of air pollution has become a priority concern of society. The United States and other countries have developed elaborate regulatory programs aimed at requiring factories and other major sources of air pollution to install the best available control technology (BACT) for removing contaminants from gaseous effluent streams released into the atmosphere. The standards for air pollution control are becoming increasingly stringent, so that there is a constant demand for ever more effective pollution control technologies. In addition the operating costs of running pollution control equipment can be substantial, so there is also a constant demand for more energy efficient technologies.

[0004] Two well known types of devices to remove common particulates from a gaseous effluent stream are electrostatic precipitators (ESPs) and fabric filter baghouse (FFB) collectors. ESPs are generally recognized as being capable of a high particle collection efficiency of fine particles when the particles have the proper electrical resistivity. FFBs are also generally recognized as being capable of a high particle collection efficiency of fine particles when the particles have the proper characteristics. Typically, pollutant gases are conditioned such that the particulates can be more efficiently filtered by ESPs or FFBs.

[0005] However, ESPs and FFBs do not remove many gaseous species. Certain species of acid-forming gases can penetrate conventional particulate collection devices such as ESPs or FFBs resulting in emissions violations, causing downstream corrosion of components, and contributing to visible condensed particles which form typically after exiting the stack. In particular, ESPs and FFBs do not remove sulfur dioxide, hydrogen chloride, or other gases that form acids when dissolved in water.

[0006] The acid-forming gases that may be released from an air pollution control system with ESPs or FFBs may violate pollution control standards, may contribute to the “detached plume” phenomena and may contribute to acid rain. Consequently, pollution control systems for applications generating large quantities of acid forming gases, such as coal-fired power plants, often require additional means to scrub acid forming gases from the effluent stream. Other applications where the emission of acid forming gases may be a problem include small coal-fired boilers, municipal waste incinerators, and medical waste incinerators.

[0007] Acid forming gases may contribute to the formation of visible plumes of effluent that violate opacity regulations even thought the total quantity of acid forming gases released into the atmosphere is comparatively minor. For example, one air pollution control problem for cement plants is the formation of a detached plume. Experimental studies have identified the detached plumes as being comprised primarily of ammonium sulfate and ammonium chloride particulates that form in the effluent, flow and condense as the emissions from the stack cool in the atmosphere a distance from the stack. The ammonium particulates are in a size range of approximately one micron, which is a size that is efficient at scattering and reflecting light. The small size of the particulates and their high scattering efficiency means that an optically opaque plume can be comprised of a comparatively small total mass of ammonium sulfate and ammonium chloride particulates. These detached plumes consist of a fine white plume that may last for hours or days depending on plant and atmospheric conditions. The plumes are highly noticeable and may violate pollution control regulations for opacity, and are thus a potentially serious problem.

[0008] Modem cement plants typically use ESPs or FFBs to reduce particulate emissions. However, these particulate filters do not remove the component chemicals that form detached plumes. In particular, ESPs and FFBs do not capture gaseous sulfur dioxide and gaseous hydrogen chloride which contribute to the chemical reactions that form detached plumes. In principle, an additional chemical scrubber could be added immediately after an ESP or FFB. However, conventional methods to scrub acid forming gases are typically expensive and inconsistent with the economic operation of an energy efficient plant. For example, conventional wet scrubbers, which commonly use spray droplet sizes greater than 1000 microns, typically use 10-100 gallons per minute of scrubbing liquid to scrub 1000 cubic feet per minute of effluent gases (1-10 kilograms of liquid per kilogram of gas). Consequently, the consumption of water, scrubbing chemicals, and energy is large for conventional liquid scrubbers. In addition, conventional liquid scrubbers have high maintenance costs.

[0009] Modern energy efficient cement plants typically use two methods to cool and condition hot process gases before they enter an ESP or FFB. In a first stage of cooling, a gas conditioning tower (GCT) uses a spray of water to cool and condition the gaseous effluent. A second stage of cooling and conditioning is performed when the feed mill is operational by contacting the partially-cooled effluent with the cool wet limestone of the feed mill supplying fresh meal to the kiln.

[0010] Typically, the hot cement kiln gases must be cooled to approximately 150° C. to provide efficient collection in an ESP or cooled to approximately 180° C. to protect a FFB from overheating. When the feed mill is on, the gas conditioning tower typically must only cool the gaseous effluent to around 250° C. In the mill-on state, the effluent is further cooled to between 100° C. to 150° C. as a result of contact with the feed meal. However, when the feed mill is shut off, the cooling tower must provide all of the cooling. There are thus two distinct operational states of the cement plant, corresponding to a mill-on and a mill-off condition.

[0011] One solution to the problem of sulfur dioxide emissions from a cement plant is to inject a lime slurry into the spray used to cool the GCT. A lime slurry is a desirable scrubbing material in a cement plant because lime is chemically compatible with other chemical constituents of cement, such that cement will not be contaminated if small quantities of lime enter the feed meal subsequent to the GCT. The chemicals in the lime slurry react with sulfur dioxide to produce thermally stable salts, thereby reducing sulfur dioxide emissions. However, conventional approaches to injecting a lime slurry into the cooling water of a GCT have low collection efficiencies and consume large quantities of lime slurry (see, e.g., Satish H. Sheth, “SO₂ Emissions History and Scrubbing History”, pp. 213-217, 33^(rd) IEEE Cement Industry Conference, Mexico City, Mexico May 1991). Conventional approaches to reducing sulfur dioxide emissions from cement plants are not consistent with high sulfur dioxide collection efficiencies (e.g., greater than about 50%) with low molar ratios (e.g., less than about 3) of calcium hydroxide to sulfur dioxide. In some applications the maximum achievable sulfur dioxide collection efficiency may be unacceptably low, even at extremely high molar ratios of calcium hydroxide to sulfur dioxide. The large lime consumption required in conventional lime slurry injection schemes increases the operating cost and exacerbates the problems of the clogging and plugging of valves and nozzles. Additionally, the cost of the lime is further increased in conventional lime slurry injection schemes utilizing filtered slaked lime because only a fraction of the slaked lime ends up in the filtered slurry.

[0012] There are several factors that have previously made the use of a lime slurry in a GCT spray an inefficient and impractical means to scrub acid-forming gases in conventional pollution control systems used in cement plants. Some of these factors tend to limit the collection efficiency. Generally, the total quantity of spray in a GCT is kept as low as possible to reduce energy costs and water consumption and to minimize the temperature drop through the tower. This reduces the total volume of spray droplets that can absorb gases. The evaporative lifetime of spray droplets in a GCT is also short, typically a few seconds, which reduces the time available for gases to be absorbed. Also, the chemical reaction rates of a lime slurry with the absorbed acid-forming gases may be comparatively slow. In conventional approaches the acid forming gases are not adsorbed and converted into salts in the spray droplets at a fast enough rate to efficiently collect sulfur dioxide using low molar ratios of calcium to sulfur.

[0013] Other factors that may make use of a lime slurry in a GCT spray inefficient or impractical are the need to limit or eliminate from the final product alkali material or the salts resulting from the reaction of the lime with acid forming gases, and the need to minimize the deposition of lime-reacted solids from accumulating within a plant. Alkali materials and salts have low volatility and thus accumulate with time, caking up within plant process equipment and presenting corrosion or plugging problems. One conventional method of reducing unwanted alkali deposits is to modify the plant to include an alkali bypass to condense these materials. An alkali bypass, for example, is installed at the kiln outlet to quench some of the gases and collect the alkali materials. Although this is effective, it tends to consume large amounts of energy, which decreases the overall system efficiency, and also removes some of the economically valuable kiln dust along with the alkali condensate.

[0014] There are also other applications, such as small coal-fired boilers, municipal waste incinerators, and medical waste incinerators, where the use of a scrubbing spray comprised of a lime slurry is desirable. Lime is a comparatively safe scrubbing chemical whose chemical components are consistent with many different pollution control systems. However, scrubbing acid-forming gases with a spray containing a lime slurry may also be prohibitively expensive in these applications because of slow reaction dynamics and a low reaction efficiency. The inventors believe that there are numerous potential applications for a scrubbing spray comprised of a lime slurry that are rendered impractical because of the poor collection efficiency and large quantities of lime required using conventional approaches.

[0015] What is desired is an apparatus and method that permits acid forming gases to be efficiently and economically scrubbed using a spray composed of a cooling liquid and an alkaline chemical. In addition, an apparatus and method is needed to selectively remove both unreacted chemical and reaction products of the scrubbing process from the scrubbed gases.

SUMMARY OF THE INVENTION

[0016] The present invention generally comprises an apparatus to create a spray of fine droplets composed of a cooling liquid and an alkali chemical. A two-fluid nozzle is used to create spray droplets preferably having a mean diameter less than about 200 microns. A source of alkaline chemical is injected at a controlled rate into the liquid before it is sprayed. In the case of alkaline earth chemicals, the chemicals must have finely ground hydrated lime particles with a mean diameter less than about 25 microns. Preferably, the mean diameter of these particles is between one to ten microns.

[0017] One aspect of the present invention is that the mean particle diameter may be selected such that the particles rapidly release chemical into the spray droplets and substantially dissolve during the evaporative lifetime of a droplet. In one embodiment the source of alkaline chemical is hydrated lime particles. Still another aspect of the present invention is that the mean diameter of the spray droplets may be controlled to increase the surface-to-volume ratio of spray droplets, increasing the absorption rate of sulfur dioxide and other acid-forming gases. Yet another aspect of the present invention is that the characteristics of a spray composed of a liquid and lime slurry may be selected to achieve an efficient sulfur dioxide scrubbing function in a chamber, such as a gas cooling tower.

[0018] Another aspect of the present invention is to provide an apparatus and method for the removal of contaminants from a gas stream by reacting the contaminants with an alkali-containing spray to produce particles that can be efficiently removed from the gas. In one embodiment, the amount of hydrated lime or other alkali in each droplet is chosen to result in reaction products having a size and density that allows for efficient separation. In another embodiment, the reaction product diameter is sufficiently different from the size of other entrained dust to allow preferential removal of the reaction products.

BRIEF DESCRIPTION OF THE DRAWINGS

[0019]FIG. 1 is a graph showing the relationship between particulate emissions and gas temperature in an electrostatic precipitator used in a modem cement plant.

[0020]FIG. 2 is a process flow diagram of a typical modem cement plant showing the air pollution control equipment and raw feed mill.

[0021]FIG. 3 is a process flow diagram of a first embodiment of the present invention in which additional injectors permit an alkaline solution or an alkaline earth slurry spray from the nozzles in the gas conditioning chamber.

[0022]FIG. 4 is a plot of calculated sulfur collection efficiency versus molar ratio of calcium to sulfur for a gas conditioning chamber in which the spray droplets have a mean evaporative lifetime of approximately three seconds.

[0023]FIG. 5 is a plot of calculated sulfur dioxide collection efficiency versus molar ratio of calcium to sulfur for a gas conditioning chamber in which the spray droplets have a mean evaporative lifetime of approximately two seconds.

[0024]FIG. 6 is a process flow diagram of a second embodiment that is similar to that of FIG. 3 having an in-line mill to form the alkaline earth slurry.

[0025]FIG. 7 is plot of the particle distribution of kiln dust and kernels by weight percent after the reaction of alkali-containing sprays with acid gases.

[0026]FIG. 8 is a process flow diagram of a third embodiment of the present invention, in which contaminant-containing kernels are selectively removed from the process gas stream in a separation unit.

[0027]FIG. 9 is a process flow diagram of a fourth embodiment of the present invention, in which contaminant-containing kernels are selectively removed from the process gas stream in a combined conditioning chamber/kernel separator.

[0028] Reference symbols are used in the Figures to indicate certain components, aspects or features shown therein, with reference symbols common to more than one Figure indicating like components, aspects or features shown therein. The reference symbols used herein are not to be confused with any reference symbols used in the items that have been incorporated herein by reference.

DETAILED DESCRIPTION OF THE INVENTION

[0029] There are many pollution control applications where it is desirable to have a cost efficient means to scrub sulfur dioxide and other acid-forming gases using a comparatively safe and ecologically friendly scrubbing spray of an alkaline solution or an alkaline earth slurry. Spray droplets absorb sulfur dioxide and other acid forming gases to form acids in the spray droplets. For example, sulfur dioxide reacts with water and oxygen in spray droplets to produce sulfurous and sulfuric acid. According to the present invention, hydrated lime, for example, in spray droplets reacts with absorbed sulfurous acid in the droplet to bind up sulfur dioxide in the form of a thermally stable calcium sulfate salt according to the reaction: Ca(OH)₂+H₂SO₃+½O₂→CaSO₄(s)+2H₂O(1). Calcium sulfate is thermally stable at temperatures greater than 1200° C. Similarly, hydrated lime reacts with hydrochloric acid in a droplet to bind up chlorine as a thermally stable calcium chloride salt according to the reaction: Ca(OH)₂+2HCl(aq)→CaCl₂(aq)+2H₂O. Calcium chloride is thermally stable at temperatures greater than 1600° C.

[0030] However, calcium hydroxide has not been commonly used as the primary scrubbing agent in sprays used to scrub sulfur dioxide or hydrogen chloride from gaseous effluents. The cost of using calcium hydroxide as a primary scrubbing agent is prohibitively expensive in many applications because large quantities of water and lime are required to achieve sulfur dioxide collection rates of greater than 80%. In some cases, the large quantities of water and lime are inconsistent with other objectives. For example, a pollution control system that uses large quantities of lime may have problems with clogging and plugging of valves, nozzles, and pipes. Consequently, there are many potential applications where it has been impractical to use hydrated lime as a scrubbing agent to scrub sulfur dioxide and other acid-forming gases from a gaseous effluent.

[0031] The present invention generally comprises an apparatus to economically produce a spray composed of a liquid and a hydrated lime slurry that is efficient at scrubbing acid-forming gases. In many applications the spray will also serve to cool the gas flow. The usefulness of the present invention is illustrated with reference to the particular problem of controlling the emissions of acid-forming gases from a modem cement plant. However, the teachings of the present invention are generally applicable to other pollution control systems where it is desirable to efficiently scrub acid-forming gases using a spray comprised of comparatively small quantities of water and neutralizing chemicals.

[0032] Modem cement plants often use electrostatic precipitators (ESPs) to control the emissions of particulates from the plant. ESPs are generally recognized as being capable of a high particle collection efficiency, especially of fine particles when the particles have the proper electrical resistivity (see, e.g., Tassicker and Schwab, “High Intensity Ionizer For Improved ESP Performance, pp. 56-58, EPRI Journal (June/July 1977)). The optimum range of dust resistivity in situ is typically between 10⁹ and 10¹¹ ohm-cm. In many industrial applications, the suspended dust particles in the effluent gas streams are not in this range for the gas conditions entering the ESP. Therefore, the dust particles must be conditioned prior to entry into the ESP by changing the gas temperature or increasing the moisture content of the gases or both (see, e.g., G. Werner, “Electrostatic Precipitators In Cement Plants”, International Cement Review (August 1991) pp. 61 et seq.; and J. R. Riley and John M. Tate, “Re-evaluating Evaporative Gas Conditioning: Is Feasibility Still An Issue?” International Cement Review (November 1990), pp. 36, et seq.). FIG. 1 is a graph of particulate emissions (mg/Nm³) from a cement kiln/preheater tower versus the temperature (° C.) of the effluent entering the ESP when the gases are conditioned by the evaporative cooling of water. As can be seen in FIG. 1, hot cement kiln/preheater tower gases (≈400° C.) must be cooled to around 150° C. to have acceptable particulate emissions of ≦50 mg/Nm³ from an ESP.

[0033] The prior art pollution control system shown in FIG. 2 is representative of a modern, energy-efficient air pollution control system for a cement plant with an ESP that addresses the problem of meeting stringent air pollution control regulations for particle emissions. As shown in FIG. 2, in a modem pollution control system for a cement plant, hot gases from a preheater tower (not shown) enter a gas conditioning chamber, which may for example be gas conditioning tower (GCT) 10. (The gas flow entering GCT 10, which includes raw meal dust and kiln dust, is shown schematically by flow arrow 15.) Gases entering the GCT may be as hot as 400° C. Nozzle means 50 located within GCT 10, near the entrance thereto, inject a spray of cooling liquid into the hot gas flow in the tower. As depicted, nozzle means 50 preferably comprises a plurality of individual nozzles 55, in order to ensure that the injected spray is evenly distributed into the gas flow, thereby promoting uniform cooling. Preferably, individual nozzles 55 are two-fluid nozzles connected by supply pipes 56 and 57 to a source of water and compressed air, respectively. The flow of water and air to the nozzles is modulated by valves 58 and 59, respectively. Valves 58 and 59 are controlled by logic and control system 60 to maintain a spray of desired quantity and characteristics. Logic and control system 60 preferably is also used to monitor various system parameters and to adjust the spray as conditions change. As is known in the prior art, for example, a temperature sensor 70 may be placed near the exit of GCT 10 to monitor the temperature of the gas flow leaving the GCT. Logic and control system 60 uses the information from the temperature sensor 70 to determine whether the temperature leaving GCT 10 is within a desired target range. If the temperature is outside of the target range, logic and control system 60 responds by increasing or decreasing the quantity of the spray accordingly. Other sensors may also be employed and connected to the logic and control system, such as sensors (not shown in FIG. 1) for measuring the temperature of gases flowing into GCT 10.

[0034] Gases, including raw feed and kiln dust, exit GCT 10 via outlet 80 as shown by flow arrow 110 preferably flow into a raw feed mill 20 to help dry and preheat the wet limestone used in the cement plant, and then on to electrostatic precipitator (ESP) 30. However, during a raw mill upset or when the raw feed mill is not in operation, gases flow directly from GCT 10 to ESP 30 as shown by flow arrow 40. After leaving ESP 30, the gases are exhausted into the atmosphere via stack 90. The gases are propelled through the air pollution control system using fans 101 and 102.

[0035] The spray characteristics of the two-fluid nozzles 55 can be altered by adjusting the pressure of compressed air and water supplied to the nozzle. In particular, both the quantity of water and the mean size of the water droplets exiting the nozzle may be controlled. A two-fluid nozzle, such as the MICROMIST™ nozzle manufactured by Envirocare International Inc., has spray characteristics that can be suitably adjusted. Typically, the droplet size is adjusted such that the droplets totally evaporate before they exit the GCT, while the quantity of water is adjusted to achieve the desired gas output temperature (e.g., 250° C. for mill-on and 150° C. for mill-off conditions).

[0036] Under normal operating conditions, the gases in the system are directed to raw feed mill 20; (this condition will be referred to as the “mill-on” condition). As noted above, the feed stock in feed mill 20 is cool and wet, and presents a relatively large surface area to the hot gases entering the feed mill. Thus, as hot gases from GCT 10 pass through the feed mill they are further cooled and moisturized.

[0037] While the pollution control system of FIG. 2 is an example of a modem pollution control system that is effective at removing common particulates, it does not address the problem of reducing the concentrations of acid-forming gases, such as sulfur dioxide and hydrogen chloride, in the gaseous effluent stream.

[0038] As shown in FIG. 3, the present invention generally may be used in connection with a modem pollution control system (as previously described with reference to the prior art of FIG. 2) with an additional chemical source 61 and a controllable chemical injector 62 to add a controlled quantity of chemical to the liquid sprayed from nozzles 55. Injector 62 receives inputs from logic and control system 60. The chemical source could comprise concentrated alkaline solutions or dry alkaline earth materials, such as hydrated lime, having a small particulate size. Commercially available sources of fine dry hydrated lime may be produced by a variety of methods, such as those produced according to the method of U.S. Pat. No. 5,233,239. Select commercially available sources of fine dry particles of hydrated lime are available with particle sizes on the order of one to ten microns (Mississippi Lime, Ste. Genevieve, Mo., and Chemical Lime, Fort Worth, Tex.), providing a large surface area for chemical reactions. However, commercially available sources of dry particles of chemically active hydrated lime are comparatively expensive. Hydrated lime particles with a particle diameter of less than 10 micron typically cost approximately $100 per ton. However, shipping costs may also be substantial, particularly in remote locations. Fine, dry hydrated lime particles also have the disadvantage that they must be stored in an inert environment until they are used because of the high chemical reactivity of the hydrated lime. Specifically, atmospheric carbon dioxide readily reacts with hydrated lime to form calcium carbonate, according to the expression: Ca(OH)₂+CO₂→CaCO₃(s)+H₂O(1). This reaction is undesirable because calcium carbonate is comparatively unreactive with acid-forming gases.

[0039] According to the present invention, slurry source 61 comprises an in-line wet-mill to convert a typical slaked lime slurry into a hydrated lime slurry with a controlled fine particle size. Pebble lime, which consists of coarse, pea-sized particles of CaO, is a comparatively inexpensive and widely available source of CaO. Pebble lime can be obtained from a wide variety of sources, typically at a cost of approximately $60-$80 per ton. The pebble lime may be stored under atmospheric conditions until it is slaked and ground. Only a thin “skin” at the surface of the pebble lime is able to react with atmospheric carbon dioxide to form calcium carbonate. The lime in the interior of the pebble lime is protected and retains its chemical reactivity until it is slaked and ground. On-site grinding of slaked lime or coarse hydrated lime offers an economical means to create the slurry source 61 of chemically reactive hydrated lime with a small particle size. Those skilled in the art are familiar with combinations of slakers, grinders, mills, and classifiers or hybrid mills that perform a classification function simultaneously with the milling or grinding function. Commercially available slakers, grinders, and classifiers are capable of economically producing large quantities of slaked, ground pebble lime with particles having a controlled mean diameter in the range of one micron to twenty-five microns. Preferably, the lime is slaked and then ground in a wet grinding process such that the ground hydrated lime particles are not exposed to atmospheric gases, such as carbon dioxide. Suitable wet grinders include commercially available wet ball mills. Such wet mills can be used to produced a slurry with a controlled particle size with particle sizes in the range of one micron to twenty-five microns. Smaller particles sizes typically require increased consumption of energy and result in a lower throughput.

[0040] Ground hydrated lime particles with a large surface-to-volume ratio (e.g., particles with a mean diameter of less than twenty-five microns) react rapidly with air. Preferably, according to the present invention the slurry is maintained in an inert ambient environment, such as a sealed or nitrogen purge storage tank. If the slurry is stored in an inert ambient environment, it may be stored for relatively short periods (e.g., less than 24 hours) without substantially decreasing its chemical reactivity. Preferably, however, the slurry is prepared substantially as needed using an in-line mill 63 (shown in the second embodiment of FIG. 6) as the slurry source 61 to ensure the highest chemical reactivity of the ground hydrated lime particles in the slurry. Experiments by the inventors indicate that fine particles of hydrated lime can rapidly lose their chemical reactivity if care is not taken to limit potential exposure of the fine particles to atmospheric carbon dioxide. The inventors believe that stringent processing conditions (e.g., reduced exposure to carbon dioxide using the above-described techniques) are required to maintain the chemical reactivity of fine hydrated lime particles (e.g., hydrated lime particles with a diameter less than 25 microns) because of the large surface-to-volume ratio of fine hydrated lime particles.

[0041] Prior art cooling tower systems, as in FIG. 2, have mean spray droplet lifetimes that are typically slightly less than half the transit time of gases through the GCT. The present invention has the flexibility to provide the same cooling effects. Specifically, one embodiment of the present invention provides for controlling nozzles 55 is by logic and control system 60 to achieve the desired cooling function (e.g., reducing the gas temperature from 400° C. to 150° C. for the mill-off condition). In another embodiment, the mean diameter of the spray droplets is selected to have a diameter of 120 to 150 microns such that the droplets completely evaporate a comparatively short distance prior to the exit of the GCT.

[0042] It is also desirable to prevent plant shutdowns caused by clogged or damaged nozzles and pipes. Preferably, the nozzles are adapted to be chemically resistant to the slurry and further adapted to prevent clogging. The pluggage of nozzles will depend upon the concentration and size of lime particles in the slurry. Preferably, the concentration of lime particles is kept as low as possible consistent with the desired scrubbing function. It is also desirable to prevent the scaling of pipes. The solubility of a lime slurry decreases with increased temperature. This can result in scaling of pipes through which slurry is transported if the temperature of such pipes substantially increases in the GCT. Preferably, the temperature of pipes transporting slurry in the GCT is maintained at a low enough temperature such that scaling is substantially prevented. One technique to prevent scaling is to use jacketed spray lances to provide a means to cool pipes transporting slurry by flowing air or water through interior of the jacketed lances.

[0043] According to the present invention, the cooling spray of a GCT can be modified to efficiently scrub acid-forming gases using comparatively small amounts of an inexpensive alkaline or alkaline earth material, such as a hydrated lime slurry. As is well known to those skilled in the art of chemistry, alkaline or alkaline earth chemicals may react with acid-forming gases to form thermally stable salts such that the acid-forming gas components are captured. However, an alkaline earth slurry would ordinarily not be expected to be a cost-effective, efficient means to scrub acid-forming gases in a GCT used in a cement plant. The evaporative lifetime of a spray droplet in a modern GCT used in a cement plant is commonly about three seconds, although it may vary from one-to-five seconds. This is a relatively short time period for acid-forming gases to absorb into the surface of a droplet, diffuse through the droplet, and react with calcium hydroxide ions released from the slurry particles in the droplet. Moreover, in order for the reaction to be rapid and efficient, the hydrated lime particles suspended in the spray droplets should substantially dissolve during the transit time and evaporative lifetime of the droplet.

[0044] According to the present invention, the spray liquid in a conventional GCT can be modified to perform an efficient scrubbing function. As is known, the total quantity of spray is kept as low as possible in a GCT and the evaporative lifetime is short. In order for the spray in a GCT to perform an efficient acid-forming gas scrubbing function the individual droplets should rapidly absorb pollutant gases and chemical agents in the droplets should rapidly scrub (e.g., react with) the pollutant gases. Additionally, chemical scrubbing agents and reacted products should otherwise be compatible with the economic operation of a cement plant. It is desirable that the cost of the chemical scrubbing agent should be low and the chemical scrubbing agent and reacted products not damage or clog pipes, valves, or fittings in the cement plant. It is also desirable that the scrubbing chemical not contaminate the feed meal or deleteriously alter the alkali balance of the feed meal.

[0045] Several aspects of the present invention make an efficient scrubbing process using an alkaline or alkaline earth chemical feasible. First, the present invention utilizes a two-fluid nozzle. Modern two-fluid nozzles, such as the MICROMIST™ nozzle, are capable of substantial control of median droplet size and with a narrow distribution in droplet size (by adjusting the compressed air pressure). The use of such a two-fluid nozzle facilitates an efficient scrubbing process because: 1) the initial surface-to-volume of the droplets is large such that the absorption of gases is rapid; 2) most of the droplets have substantially the same initial diameter and hence substantially the same quantity of slurry particles, which facilitates uniform chemical reaction dynamics in the droplets; and 3) each droplet will have a similarly large lifetime (typically one-to-five seconds), since the median droplet size is selected such that the droplets evaporate proximate to the exit of the GCT. Second, the present invention can use a finely ground hydrated lime that is highly reactive. A finely ground hydrated lime with a mean diameter in the range of one-to-twenty-five microns is highly chemically reactive, in large part because it has an extremely large surface area relative to its volume. The large surface-to-volume ratio of the hydrated lime particles increases the rate at which calcium hydroxide dissolves in the spray droplets. Decreasing the mean diameter of the hydrated lime particles substantially below 25 microns facilitates faster dissolution of the hydrated lime particles. According to the present invention, the release of calcium hydroxide from the dissolving hydrated lime particles preferably occurs at a rapid enough rate that it does not limit the reaction that converts absorbed acid-forming gases into salts. A scrubbing process is likely to achieve a low molar ratio of calcium to sulfur if hydrated lime particles from the injected slurry substantially dissolve in the droplets before the droplets evaporate. For common GCT evaporative lifetimes of one-to-five seconds, the hydrated lime particles preferably have a mean diameter between one-to-ten microns such that the hydrated lime particles substantially dissolve in spray droplets in the GCT during their evaporative lifetime as ions are consumed.

[0046] Preferably, the spray droplet size is selected to achieve a high collection efficiency. However, there are tradeoffs between the surface area of spray droplets and their evaporative lifetime. GCTs used in cement plants typically use spray flow rates corresponding to about one gallon per minute (GPM) per 1000 cubic feet per minute of effluent gas flow (0.1 kilogram of liquid per kilogram of gas). For a constant quantity of spray liquid, decreasing the spray droplet size increases the initial surface area of the droplet but also decreases the evaporative lifetime of the droplets. For example, for plant conditions corresponding to the mill-off state, spray droplets with an initial diameter of 250 microns have an evaporative lifetime of about 5 seconds. By way of comparison, if the same quantity of liquid is sprayed as droplets having an initial diameter of 50 microns, the surface area increases by a factor of 25. However, the evaporative lifetime in the mill-off state for droplets having an initial diameter of about 50 microns is reduced to less than one second. Smaller spray droplets have a larger surface area to absorb gases but have a comparatively shorter evaporative lifetime for chemical reactions to occur inside the droplet. The unreacted alkali and the salts that are the product of the reaction of the alkali with acid forming gases generally have a low volatility. At the end of the evaporative lifetime, a solid “kernel” containing these materials remains. The size of each kernels is controlled by the initial amount of lime, or other alkali, initially present in the drop and the scrubbing reactions. The ability to control the size range of kernels and some practical consequences of this control will be discussed subsequently.

[0047] One important variable in deciding how much lime slurry to inject is related to the spray characteristics (droplet size and total quantity of liquid sprayed) which is also a function of operational state (mill-on or mill-off). The pH should be selected such that salts are formed at a rapid rate in the spray. A high pH (e.g., greater than 12) increases the solubility of acid-forming gases in the droplets. Preferably, the spray is a saturated lime solution with a pH approaching a saturation limit of about 12.

[0048] In cement plant applications a high pH is also desirable because it reduces the solubility of ammonia in spray droplets. The absorption of ammonia in such plants is undesirable, as ammonium sulfate salts are not thermally stable at common GCT temperatures (e.g., greater than 235° C.). Any ammonium sulfate formed in a droplet can decompose when the droplet evaporates, re-releasing ammonia and sulfur dioxide. Additionally, ammonia-containing particles are likely to be collected by dust collection systems and be recycled into the plant. In either case, this reduces the efficiency of the reactions that convert acidic gases into thermally stable salts. The efficiency of the scrubbing process thus increases when the quantity of lime slurry is increased such that the droplets retain a high pH during their evaporative lifetime in the GCT.

[0049] The dependence of sulfur dioxide collection efficiency as a function of lime particle size in a gas cooling tower has been experimentally measured by the inventors. The experimental techniques to measure sulfur dioxide collection efficiency are well known to those skilled in the art. FIG. 4 is a plot of sulfur dioxide collection efficiency versus the molar ratio of calcium to sulfur. As shown in FIG. 4, there is strong dependence of sulfur dioxide collection efficiency on the lime particle size. The experimental conditions correspond to 257,800 kg/hr of hot gases with 56 kg/hr of sulfur. The input temperature of the gas was 375° C. The spray characteristics were adjusted to achieve an output temperature 140° C. and an evaporative lifetime of approximately 3 seconds. The collection efficiency was calculated for hydrated lime particles with a diameter of 3 microns, 10 microns, and 30 microns. The collection efficiency rises with increasing calcium to sulfur ratios (e.g., a higher concentration of slurry) but tends to plateau at high calcium to sulfur ratios. A collection efficiency of 90% can be achieved with a calcium to sulfur molar ratio of one for the 3 micron diameter lime particles. This means that a comparatively small quantity of hydrated lime may be used to efficiently scrub sulfur dioxide. This reduces operating costs and helps prevent clogging and plugging of valves and nozzles.

[0050] The above described experiment was also performed under identical conditions except with the spray characteristics adjusted to achieve an evaporative droplet lifetime of approximately two seconds. As shown in FIG. 5, the plot of calculated sulfur dioxide collection efficiency versus calcium to sulfur molar ratio are strongly dependent on the size of the lime particles and the calcium to sulfur ratio. However, the collection efficiency is reduced slightly compared to the case where the evaporative droplet lifetime is three seconds.

[0051] The present invention permits sulfur dioxide to be efficiently scrubbed using a relatively small quantity of lime. The inventor attributes the very high efficiency of the present invention to the small size of the hydrated lime particles and the comparatively small size of the spray droplets. The spray droplets preferably have an initial mean diameter less than 200 microns such that they have a large enough surface area to absorb a large load of acidic gases during their evaporative lifetime. Additionally, the hydrated lime particles have a large enough surface-to-volume ratio that they can rapidly release the calcium and hydroxide ions in the spray droplets. The high SO₂ collection efficiency and low molar ratios of hydrated lime to sulfur dioxide that has been demonstrated indicate that fine particles of lime (e.g., particles with a mean diameter less than 5 microns) substantially dissolve in the spray droplet during the two-to-three second evaporative lifetime of spray droplets.

[0052] Although the experimental results for sulfur dioxide collection efficiency have been described, similar behavior has been observed for other acid-forming gases, such as hydrogen chloride. The large surface-to-volume ratio of the spray droplets and the fine hydrated lime particles favor the rapid absorption and conversion of other acid-forming gases into thermally stable salts.

[0053] The scrubbed gases exiting outlet 80 carries raw feed dust, kiln dust and kernels of reacted or partially reacted scrubbing material. One conventional approach to handing kernels from a scrubbing system is to allow both the dust and kernels to be captured and recirculated through the cement process, allowing for recovery of valuable kiln dust. This may result in kernels becoming incorporated into the cement, which may present a quality control problem. Specifically, the presence of the kernels, which can contain unreacted alkali, or reacted alkali in the form of sulfur- or chlorine-containing salts, can modify the properties of the final cement product. In addition, material that is not incorporated into the clinker or otherwise removed from the process flow can eventually condense out of the process gas, presenting a maintenance problem. The accumulation of condensable material is conventionally controlled with an alkali bypass, in which a portion of the gas is diverted and cooled to condense out less volatile species. The condensate can then be removed from the process stream. While an alkali bypass is effective, it consumes large amounts of energy and wastes valuable kiln dust that is removed along with the condensate.

[0054] Removal of the kernels by separation from the scrubbed gases and kiln dust at the exit of the GCT 10 is one way of mitigating these problems. The following examples illustrate the inventive method and apparatus as applied to separation of particles resulting from a scrubbing process in a cement plant. The teachings contained herein may be modified or may be applied to other processes as would be obvious to those skilled in the art. In addition, many methods and apparatus for separation of particles from a gas flow are know in the art. The following examples are not intended to limit the scope of the present invention.

[0055] The present invention provides for a solution to problems resulting from alkali addition by selectively removing kernels from the gas, while leaving the kiln dust for recirculation. By properly selecting the size and concentration of alkali in a cooling tower spray, it is possible to generate kernels that are separable from both the kiln exhaust and the kiln dust. Kiln dust is generated with a wide range of sizes in various mills and is filtered by having gone through the cement making process, either by being incorporated into the clinker, by being deposited on walls, or by passing into baghouses. As a result, the dust passing through the GCT has a rather limited range of sizes and densities. Kernels are formed within the GCT from reacting alkali-containing drops, and thus have a size range determined by the amount of reactant in each drop. FIG. 7 presents a graph of the typical size distribution of particles exiting a conditioning tower (as in outlet 80, for example). The curve of FIG. 7 has been experimentally determined using a slurry containing microfine lime and as measured with absorption spectroscopy. This curve is bimodal, with one maximum at a particle size, or diameter, of approximately 2 μm and a second maximum at a particle size of approximately 30 μm. As indicated in FIG. 7, the peak indicative of smaller particles is primarily due to kiln dust, and the peak indicative of larger particles is primarily due to kernels.

[0056] For the conditions for which the curve of FIG. 7 was obtained, the amount of lime in each drop, which had an initial diameter of about 120 to 150 μm, was varied to give kernels having a mean diameter of from 20 to 40 μm. As shown in FIG. 7 the mean aerodynamic particle diameter of kiln dust ranged from 0 to about 9 μm, while the kernels ranged in size from about 20 μm to about 40 μm. The kiln dust is found to have a specific density of from 1.5 to 2.5 gm/cm³, and the kernels have a density of from 1.5 to 2.0 gm/cm³. The similar densities and differences in size can be used to selectively separate the particles from the gas according to their origin.

[0057] A third embodiment of the present invention, as shown in the process flow diagram of FIG. 8, provides for separating the kiln dust from the kernels according to the size difference of the two types of particles using a cyclone separation unit 801. The flow leaving the GCT 10 from outlet 80 is separated into three components—1) kernels that settle to the bottom of GCT 10 and are removed as flow 800A; 2) kernels that are separated from the scrubbed gases using the cyclone 801 and removed as flow 800B; and 3) filtered flow 110′ that is used as a process gas. The separation of the flow is in contrast to the previous embodiments, where all of the gases leaving the GCT 10 were cycled through the balance of the plant as a process gas. In this embodiment the process gas 110′ contains scrubbed kiln gases and a majority of the kiln dust from the GCT 10. As a result nearly no alkali or reacted alkali salts containing sulfur, chlorine or other components of the acid forming kiln gases need be used for further processing into cement. Alternative methods for separation of kernels from the remaining gases and particles include settling chambers, electrostatic chambers, filters, or other methods or devices capable of separation of one size range of particles from another in a gas flow.

[0058] The kernels removed in flows 800A and 800B can be collected and disposed of or can be used in other parts of the cement plant, such as being used as an additive for mortar or other beneficial uses. The various options for conveying the kernels are illustrated in FIG. 8. The flow of the kernels is controlled by a valve 803 and a valve 805, which control the flow 800B from the cyclone 801 and the flow 800A from the GCT 10, respectively. Flows 800A and 800B are combined and through a three-way valve 807 become flow 809 for use in a process or are accumulated in a receiver 811 for disposal 813.

[0059] In a fourth embodiment, as shown in the process flow diagram of FIG. 9, the functions of the gas cooling tower and separation unit (for example, GCT 10 and cyclone 801) are combined in a single GCT/separator 10′. As in the third embodiment, the separation can be accomplished by variety of techniques known in the art. One particular apparatus would enlarge the GCT 10 of one of the previous embodiments and provide a flow path that would encourage particles to collect near a trap at the bottom of the GCT/separator 10′. The resulting flow 110′ would contain scrubbed gases with kernels filtered out, while the kernel flow 900 could be used similar to the combined flow 800A and 800B of the third embodiment.

[0060] Other variations on the present invention are also possible. In particular, chemical sensors 120 could be added at various sites in a cement plant to measure levels of sulfur dioxide. The slurry quantity or the properties of the slurry (e.g., particle size) could be adjusted in response to information from the chemical sensors 120 to maintain the emissions within acceptable limits.

[0061] The present invention has been described in detail for a hydrated lime slurry. However, those skilled in the art are familiar with other alkaline earth materials that form salts with acid-forming gases. Those skilled in the art are also familiar with techniques, such as using a slaker, grinder classifier, and mixer to make a slurry source comprised of small diameter alkaline earth particles of other compounds.

[0062] The present invention has also been described in detail for the GCT used in a cement plant. However, those skilled in the art of pollution control are familiar with sag other applications where a spray with an injected alkaline slurry could be used to scrub acid forming gases. For example, the spray nozzles, slurry source, slurry injector, and controller of the present invention do not necessarily have to be disposed in a GCT of a cement plant. The teachings of the present invention could be applied to scrubbing sprays used in a wide variety of applications where it is desirable to efficiently collect sulfur dioxide and other acid forming gases using a spray composed of a liquid and a hydrated lime slurry. However, if the droplets do not completely evaporate in the pollutant stream the effective lifetime of a spray droplet may more properly be defined by a mean transit lifetime in the gaseous effluent stream.

[0063] While the present invention has been described with reference to the specific embodiments and elements disclosed, it is understood that other, equivalent embodiments of the invention are possible, and that the practice of the invention is not intended to be limited solely to those embodiments disclosed in this application. 

What is claimed is:
 1. An apparatus for removing solid particles remaining from a reactive gas conditioning process comprising: a conditioning chamber for contacting a contaminant in a gas with an alkali contained within a liquid droplet, where said contaminant is an alkali-reactive contaminant, and where said contacting forms kernels having a size range when said liquid evaporates; and a separator for removing said kernels from said contacted gas.
 2. The apparatus of claim 1, wherein said contacting contacts a spray with said gas, where said spray has droplets comprising said alkali, where said droplets have a mean lifetime in said conditioning chamber, and where said mean lifetime and spray characteristics are sufficient for said spray to absorb said contaminants and for said contaminants to react with said alkali to form kernels having said size range.
 3. The apparatus of claim 2, wherein said droplets have a mean droplet diameter greater than about 100 microns.
 4. The apparatus of claim 2, wherein said alkali includes water-soluble alkaline earth particles having an initial mean diameter, wherein said droplets are a slurry including said water-soluble alkaline earth particles, and wherein said mean lifetime is sufficient for said alkali to substantially dissolve in said water.
 5. The apparatus of claim 4, wherein said mean lifetime is less than about 5 seconds and wherein said initial mean diameter is about 10 microns or less.
 6. The apparatus of claim 1, wherein said alkali is hydrated lime.
 7. The apparatus of claim 1, wherein said gas includes dust particles having a dust particle size range, wherein said kernel size range is sufficiently different from said dust particle size range, and wherein said separator preferentially separates said kernels from said dust particles.
 8. The apparatus of claim 1, wherein said separator is a cyclone separator.
 9. The apparatus of claim 1, wherein said separator is a settling tank.
 10. The apparatus of claim 1, wherein said conditioning chamber is a cooling tower.
 11. The apparatus of claim 1, wherein said separator is incorporated into said conditioning chamber.
 12. A method of removing particles from a scrubbing process comprising: contacting a spray having drops including an alkali with a gas having at least one acid-forming components for a contact time sufficient to allow said at least one acid-forming component to react with said alkali and form kernels; and removing said kernels from said gas.
 13. The method of claim 12, wherein one of said at least one acid-forming component is sulfur dioxide, wherein said kernels are solid particles including sulfur, and wherein said contact time is sufficient to produce is substantially sulfur-free contacted gas.
 14. The method of claim 12, wherein one of said at least one acid-forming component is hydrochloric acid, wherein said kernels are solid particles including chlorine, and wherein said contact time is sufficient to produce substantially chlorine-free contacted gas.
 15. The method of claim 12, wherein said alkali is a water soluble solid, wherein said spray includes water and dissolved alkali, and wherein said contacting includes absorbing said acid-forming components in said water, and reacting said absorbed acid-forming components with said dissolved alkali.
 16. The method of claim 12, wherein said alkali is hydrated lime, wherein said spray is a slurry including water containing dissolved lime and hydrate lime, and wherein said hydrated lime includes lime particles of a size sufficient to maintain a water pH of about 12 or greater.
 17. The method of claim 12, wherein said gas includes dust, and wherein said removing has an efficiency that is greater for said kernels than for said dust.
 18. The method of claim 17, wherein said removing is removing with a cyclone separator.
 19. The method of claim 17, wherein said removing is removing with a settling chamber.
 20. The method of claim 17, wherein said contacting and said removing are performed in a conditioning tower.
 21. The method of claim 12, wherein said contact time is less than 5 seconds.
 22. The method of claim 12, wherein said spray is a slurry of water and said alkali, wherein said alkali is hydrate lime.
 23. A method of using a process gas having an alkali-reactive contaminant in the production of contaminant-free cement comprising: contacting a spray having drops including an alkali with said process gas for a contact time sufficient to allow said contaminant to react with said alkali to form kernels; removing said kernels from said process gas; using said contacted process gas in the production of said contaminant-free cement.
 24. The method of claim 23, wherein said contaminant gas includes sulfur.
 25. The method of claim 23, wherein said contaminant gas includes chlorine.
 26. The method of claim 23, wherein said spray is a slurry of water and said alkali, wherein said alkali is hydrate lime.
 27. The method of claim 23, wherein said contact time is less than 5 seconds.
 28. The method of claim 26, wherein said slurry has a pH greater than about
 12. 29. The method of claim 23, wherein said gas includes kiln dust, and wherein said removing has an efficiency that is greater for said kernels than for said kiln dust.
 30. The method of claim 29, wherein said removing is removing with a cyclone separator.
 31. The method of claim 29, wherein said removing is removing with a settling chamber.
 32. The method of claim 29, wherein said contacting and said removing are performed in a conditioning tower. 